Paper-based container lids and methods for making the same

ABSTRACT

A paper-based container lid comprises a top wall, a side wall connecting to the top wall, and a sealing channel formed on the side wall for sealingly engaging a rim of the container and securing the lid to the container, wherein the top wall and the side wall are preferably formed from separate blanks.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of application Ser. No. 13/973,663filed on Aug. 22, 2013 which claims the benefit of U.S. ProvisionalApplication 61/692,065 filed on Aug. 22, 2012, entitled Paper-BasedContainer Lids and Methods for Making. Both of the foregoingapplications are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject disclosure relates to paper-based container lids and methodsof making the same, and more particularly to lids for containers, suchas beverage cups, which can be economically formed, are capable of beingused with hot liquids, and include a sealing channel that creates anenhanced sealing interface with a corresponding rim formed on thecontainer.

2. Background of the Related Art

Hot beverages, such as coffee, tea or the like, are frequently sold as atakeout item and supplied in disposable cups with thin plastic lidsfasten over the rim of drinking cups. Such lids prevent spillage andevaporation of the beverage within the cup, and help insulating thecontents of the cup from the ambient temperature by closing the cupopening. Drinking cup lids, such as those used by restaurants,convenience stores, and coffee houses, are commonly made of plastics.They are inexpensive and therefore suitable for disposable use. Awell-known method of manufacturing plastic cup lids is by vacuumforming, which is a plastic thermoforming process that involves formingthermoplastic sheets into three-dimensional shapes through theapplication of heat and pressure. During the vacuum forming process, theplastic material is heated until it becomes pliable, then placed over amold and drawn in by a vacuum until it takes on the desired shape. Thevacuum thermoforming allows cup lids to be manufactured veryinexpensively.

U.S. Pat. No. 4,589,569 discloses a disposable lid of one piece plasticconstruction that can be manufactured relatively inexpensively. The lidis manufactured by a thermoforming operation, preferably vacuum forming.The lid includes an annular mounting portion for engaging the lip of thecup; an annular side wall extending upwardly from the mounting portion;and a top wall having a drinking opening and a recess formed adjacentthe drinking opening to accommodate the upper lip of the user.

Some plastics are not biodegradable, and increasing environmentalconcerns drive the needs for inexpensive and biodegradable lids asalternatives for disposable plastic lids.

Efforts to produce paper-based lids for containers/cups have had limitedcommercial success due to the complicated manufacturing process and thepoor sealing between the cup body and the lid sealing ring that resultsin leakage of fluid contents from the cup. The poor lid sealing andleakage is worse when the cup is for hot beverages. Lids made from asingle paperboard blank do not effectively seal around the rim of thecontainers. During the manufacturing process, substantial crimps areformed in the sealing ring portion of the lid, resulting in gaps whenthe ring attaches to the rim of the container and consequently a sourceof fluid leaks.

U.S. Publication No. 2010/0243722 addresses the leaking problem by usingpaperboard lids manufactured without the substantial crimps formed inthe sealing rings. The lid includes a single contiguous moldedpaperboard body configured to conformingly couple to the container rim.The lid is formed by placing an unformed paperboard blank inside a pressmachine that uses compression forces to shape the paperboard blank intothe lid. The draw and pressure rings hold the blank in place, while themale and female mold components of the machine compress the blank into alid shape. By holding the paperboard blank with draw and pressure ringswhile the blank is pressed into the lid shape, the formation ofsubstantial crimps typically occurring during the press step can beprevented.

There have been reports of paper-based cups with integrated lids. Forexample, U.S. Pat. No. 6,592,504 discloses a disposable paperboard cupthat includes a bottom insert, and a substantially truncated conicalbody with an integral lid and a cup opening. The integral lid is movablebetween a raised position and a closed position. The lid has a free edgewith an opening that provides an access to the fluid contents inside thecup when the lid is in the closed position. The lid is formed from asemi-circular die-cut piece adjoined to the body portion of the cup. Thecup with integrated lid requires complex folding mechanisms, renderingit expensive and difficult to manufacture. Furthermore, the cup withintegrated lid possesses a wide top, which is subjected to spillage andis difficult to achieve an adequate sealing between the lid and thecontainer body, resulting in leaking of the packaged contents.

Moreover, Inmaco BV located in the Netherlands offers for sale apaper-based cup lid. A cross-section of the cup-lid interface in theInmaco product is illustrated in FIG. 13E. As shown therein, the Inmacolid 80 includes a cylindrical sidewall 82 and a top wall 81. Thesidewall 82 is spiral wound and is made out of 3 layers of paperboardand adhesive and includes a circumferentially formed bead 85 whichextends radially inward from the sidewall 82. When the lid 80 is placedon top of the rim “R” of the cup, the sidewall 82 deflects so that therim “R” of the cup can pass by the circumferential bead 85. Once passedthe bead 85, the sidewall 82 relaxes and traps the rim “R” of the cupbetween the bead 85, a flat section 87 of the sidewall 82 and the topwall 81.

As noted above, the bead 85 formed in the sidewall 82 around thecircumference of the Inmaco lid 80 secures the lid to an appropriatelysized container. The fit is fairly tight radially, i.e. there is a closematch between the outer diameter of the container rim “R” and the innerdiameter of the lid 80. However, there is not a tight fit axially; thelid 80 can move up and down and thus it does not provide good leakresistance for liquids. In fact, in the lids tested by the inventors,the lid could move up and down by as much as 1.5 mm. Moreover, since thesidewall 82 of the lid in the sealing zone is flat (section 87) and rim“R” is curved there is no mating contact between the sidewall 82 and rimsurfaces, and thus the seal is poor.

A further disadvantage of the Inmaco lid 80 is that the sidewall has aspiral seam. It is difficult to minimize the visual impact this seam bycompressing it further, because this won't necessarily make the gapbetween the ends of the sidewall blank smaller. Moreover, using a spiralwound sidewall makes it extremely difficult to register or position theseam at a specific location around the periphery of the lids. For thesereasons and to the best knowledge of the inventors, the Inmaco lid hasnot been offered commercially with a hole for drinking nor has it beenused with liquids.

An additional disadvantage of the Inmaco lid 80 is its stacking height.Because the sidewall of the Inmaco lid 80 is substantially straight,with no taper, and the bead 85 is formed radially inward, the stackingheight of the Inmaco lid 80 is limited by the location of the bead 85and the height of the skirt below the bead.

It is known that a bead or fill line in a beverage container such as apaper cup can be formed by utilizing a spinning forming disc, whereinthe disc is spun into a position near the top of the sidewall of thepaper container thereby creating a bead, groove or fill line in thesidewall of the container. This apparatus requires a cam follower in amachined cam track, a cam drive shaft in a relatively complicated headerassembly, and an auxiliary loader for the spinning disc. Thus, asubstantial number of precision moving parts are required. Such unitsare therefore relatively expensive to construct and to maintain.

To address these drawbacks, U.S. Pat. No. 4,247,277 disclosed anon-spinning apparatus for forming a fill line or groove in paper cupsor containers by axially compressing an annulus of a resilient materialinto the inside of paper cups, thereby causing a controlled deformationof the cup material outwardly about its periphery. Rather than arotating movement of the spinning disc, the apparatus relies on the up-and down-movement of the compressed resilient material for a formationof the fill line or groove. The outward deformation occurs internally ofa cup die where a portion of the sidewall of a paper cup or containerconfined within the die is forced by the compressed annulus to form thefill line or groove. While this apparatus is less complicated than thespinning forming discs previously used for the same purpose, it is stilla complicated apparatus which requires moving parts that tend to wear,require maintenance and replacement.

U.S. Pat. No. 5,637,332 discloses a simplified apparatus for forming afill line in a paper container such as a paper cup that includes nomoving parts. A fill line is formed by forcing a punch of a mating ringinto a finished cup positioned in a die which includes an annular recessspaced below the rim of the finished cup, and the annular recessterminates in a bottom edge to serve as an anvil surface for forming thefill line.

U.S. Pat. No. 6,663,926 discloses an apparatus for forming a rib on theside wall of the cup via an operation of the rib processing toolperformed outside the cup body, thereby improving the process efficiencyby eliminating a need of moving a rib processing tool in and out againstthe cup body. Furthermore, the apparatus allows the rib to be formedgradually in the circumferential direction of the cup body, inaccordance with the relative rotation between the cup body and the ribprocessing tool. Therefore, it is possible to reduce force added to thecup body during the rib formation in comparison with the case in whichthe entire rib is formed at once.

U.S. Pat. No. 7,753,832 discloses an apparatus for molding an articleproduced from paperboard or cardboard, wherein a momentary irradiationof the microwave frequency is exerted on the molded board to improve itsmoldability. To form a cup with an annular crease on the side wall, thecup is placed on a base and supported at its side wall by a carrier ringhaving an annular groove that is corresponding to the crease to be madein the cup. The apparatus includes a base to support the cup bottom; acarrier ring with an annular groove to support the cup side wall; amoving tool; a crease forming tool connected to the moving tool, whereinthe crease forming tool is corresponding to the groove of the carrierring and the crease to be created on the cup side wall. The moving toolis lowered inside the cup so that its lower end is level with the grooveof the carrier ring, and the irradiators on the moving tool exertmicrowave frequency on the side of the cup at the point where the creaseis to be formed to permanently mold the creased side wall.

Despite extensive research for paper-based container lids, particularlyfor the drinking cup lids, several drawbacks remain. Examples of suchdrawbacks described in part above include: complexity of production;lack of recyclability either due to the use of recyclable/compostablematerials or the difficulties in operating reclamation systems when thecup and the lid are made of different materials; insufficient consumeracceptance due to inadequacies in material “mouth feel” or design,decreased aesthetic appeals when the packaged fluids stain the lidmanufactured from molded pulp; and poor lid performance due toinadequate sealing of the lid to the cup, especially after several usagecycles.

Accordingly, there is still a need for paper-based container lids thatcan be produced economically and with less complicated processes thanknown paper-based lids, and which provide acceptable lid performance (ifnot enhanced) compared to known paper-based lids. Moreover, there is aneed for paper-based container lids which can be used with hot liquidsand are constructed to provide an enhanced sealing interface with thecontainers so as to minimize, if not eliminate, the leakage of contentspackaged in the containers.

SUMMARY OF THE INVENTION

The present disclosure is directed to a lid for a container thatincludes, inter alia, a paperboard side wall formed from a first blank,wherein the side wall extends about a longitudinal axis and includeslongitudinally opposed first and second ends; and a paperboard top wallformed from a second blank, wherein the first blank is different fromthe second blank. The top wall of the lid is connected to the side wallproximate the first end and the top wall includes an opening therein.

Preferably, the lid further includes a sealing channel formed in theside wall between the first end and the second end. In certainembodiments, the sealing channel projects radially outward.

It is envisioned that the side wall of the lid can include asubstantially vertical seam between the first end and the second end ofthe side wall. The seam can be compressed. Preferably, the opening ispositioned opposite of the seam.

In embodiments of the present lid disclosure, the side wall includes aninner surface which has a polymer coating; the top wall includes a lowersurface and an upper surface, wherein the lower surface and the uppersurface of the top wall each include a polymer coating. In suchconstructions, the upper surface of the top wall is connected to theinner surface of the side wall by a polymer-to-polymer bond and thelower surface of the top wall is connected to the inner surface of theside wall by a polymer-to-polymer bond.

It is envisioned that the lid of the present disclosure can include ajoint section defined by where the first end of the side wall isconnected to the top wall. In such constructions, the joint sectionincludes a top end that forms a lid rim and the lid rim includes asubstantially rounded section. In certain constructions, thesubstantially rounded section of the lid rim is oriented toward thelongitudinal axis.

In certain embodiments of the present lid disclosure, the joint sectionfurther includes a middle section below the top end, wherein the rim hasa width associated therewith, wherein the middle section has a widthassociated therewith, and wherein the width of the rim is greater thanthe width of the middle section.

It is further envisioned that the joint section of the lid can include abottom end below the middle section, and wherein the bottom end flarestoward the longitudinal axis.

In certain constructions of the present invention, the opening is formedin the lid below the rim. Moreover, the top wall can include a debossedsection, and wherein the opening is located within the debossed section.The top wall can further include an embossed section located adjacent tothe debossed section.

The present disclosure is further directed to a lid for a container thatincludes a paperboard side wall formed from a first blank and apaperboard top wall formed from a second blank. The side wall extendsabout a longitudinal axis and includes longitudinally opposed first andsecond ends, wherein a sealing channel is formed in the side wallbetween the first end and the second end. A substantially vertical seamis formed between the first end and the second end of the side wall andthe side wall includes an inner surface, wherein the inner surfaceincludes a polymer coating. In the present lid construction, the firstblank is different from the second blank. Moreover, the top wallincludes an opening and a lower surface and an upper surface. The lowersurface and the upper surface each include a polymer coating, and thetop wall is connected to the side wall proximate the first end to definea joint section. Still further, the upper surface of the top wall isconnected to the inner surface of the side wall by a polymer-to-polymerbond and the lower surface of the top wall is connected to the innersurface of the side wall by a polymer-to-polymer bond.

Preferably, the sealing channel projects radially outward.

In certain embodiments, the seam is compressed.

It is envisioned that the joint section can include a top end forming alid rim having a substantially rounded section. Moreover, the top wallcan include a debossed section and the opening is located within thedebossed section.

The present disclosure is also directed to a lid for a container thatincludes a side wall and a top wall. The side wall extends about alongitudinal axis and has longitudinally opposed first and second ends,wherein an outwardly projecting sealing channel is formed in the sidewall between the first end and the second end. The top wall is connectedto the side wall between the outwardly projecting sealing channel andthe first end of the side wall.

In certain embodiments, the side wall is paperboard and the top wall canalso be paperboard.

It is envisioned that the outwardly projecting sealing channel can havean upper portion associated therewith, and wherein the top wall isconnected to the side wall adjacent to the upper portion of theoutwardly projecting sealing channel.

Preferably, the top wall is connected to the side wall adjacent to thefirst end.

Moreover, the top wall can include an opening formed therein.

In certain constructions, the first end of the side wall defines a jointsection where the top wall is connected to the side wall, wherein thejoint section includes a bottom end and a top end, and wherein the topend forms a lid rim. Preferably, in embodiments wherein the top wallincludes an opening formed, the opening is positioned below the lid rim.

In certain embodiments wherein the top wall includes an opening formedtherein the opening is positioned approximately coplanar with the bottomend of the joint section.

Preferably, the first end of the side wall includes a flange section anda flap section which is folded over the flange section to create a lidrim. The lid rim can includes an in-curled portion.

The top wall can further includes an upwardly projection peripheralflange which is sandwiched between the flange section and the flapsection of the first end of the side wall.

Preferably, at least a portion of the side wall is arranged at an acuteangle with respect to the top wall.

In certain embodiments, the outwardly projecting sealing channel iscontinuous. Ideally, the shape of the outwardly projecting sealingchannel is selected to provide for mating contact with a container rim.

The present disclosure is further directed to a lid for a container thatincludes, among other elements, a side wall and a top wall connected tothe side wall. The side wall extends about a longitudinal axis andincludes longitudinally opposed first and second ends. A sealing channelis positioned between the first end and the second end and a seam runssubstantially vertically between the first end and the second end.

Preferably, the side wall is paperboard. Moreover, the top wall can bepaperboard.

It is envisioned that the seam can be compressed. Preferably, the seamis compressed to reduce the seam thickness to less than twice a materialthickness for the side wall. Moreover, the top wall can include anopening preferably positioned diametrically opposite of the seam.

In certain embodiments, the sealing channel extends radially outwardfrom the longitudinal axis.

Preferably, the top wall includes an opening formed in an embosseddrinking area which is positioned below an upper rim formed by the sidewall of the lid.

The present disclosure is further directed to a lid and containercombination that includes, inter alia, a container and a paperboard lid.The container having a side wall that extends about a longitudinal axisand includes longitudinally opposed top and bottom ends, the top end ofthe container including a rim. A bottom wall is connected to the bottomend of the side wall.

The paperboard lid includes a side wall that extends about thelongitudinal axis and has longitudinally opposed first and second ends,wherein an outwardly projecting sealing channel is formed in the sidewall between the first end and the second end. A top wall is connectedto the side wall between the outwardly projecting sealing channel andthe first end of the side wall, wherein the top wall of the lid contactsthe rim of the container when the rim is engaged within the outwardlyprojecting sealing channel.

Preferably, a first opening is formed in the top wall of the lid thatprovides access to contents of the container. It is envisioned that asecond opening can be provided for venting.

In certain embodiments, the rim is circular. Moreover, the outwardlyprojecting sealing channel can be a radially projecting sealing channel.It is envisioned that the shape of the outwardly projecting sealingchannel approximates the shape of the container rim.

In certain constructions of the lid and container combination, thecontainer is made from paperboard.

In is envisioned that in certain constructions, the outwardly projectingsealing channel has an upper portion associated therewith, and whereinthe top wall is connected to the side wall adjacent to the upper portionof the outwardly projecting sealing channel. Still further, the top wallcan be connected to the side wall adjacent to the first end.

The present disclosure if further directed to a lid for a container thatincludes, among other elements, a paperboard side wall and a paperboardtop wall. The paperboard side wall extends about a longitudinal axis andhas longitudinally opposed first and second ends, wherein the side wallincludes a sealing channel positioned between the first end and thesecond end, and wherein the side wall includes inner and outer surfaceseach including a polymer coating.

The paperboard top wall includes a lower surface and an upper surface,wherein the lower and upper surfaces each include a polymer coating; andwherein the first end of the side wall includes a joint section wherethe side wall is connected to the top wall such that the inner surfaceof the of the top wall is joined to the inner surface of the side wallby a polymer-to-polymer bond. Moreover, the outer surface of the topwall is joined to the inner surface of the side wall by apolymer-to-polymer bond.

In certain constructions, the sealing channel is a radially projectingsealing channel. Moreover, the sealing channel can be continuous. Stillfurther, the sealing channel can have an upper portion associatedtherewith, and wherein the top wall is connected to the side walladjacent to the upper portion of the sealing channel.

It is also envisioned that the top wall can be connected to the sidewall adjacent to the first end.

Preferably, the top wall includes an opening formed therein.

In certain constructions, the joint section includes a bottom end and atop end, and wherein the top end forms a lid rim. In embodiments whereinthe top wall includes an opening formed therein, the opening can bepositioned below the lid rim. Alternatively, the opening can bepositioned approximately coplanar with the bottom end of the jointsection.

The present disclosure is also directed to a lid for a container thatincludes, inter alia, a side wall and a top wall. The side wall extendsabout a longitudinal axis and has a first end and a second end, thesecond end being longitudinally opposed from the first end. The sidewall includes a sealing channel formed between the first end and thesecond end.

A joint connects the side wall to the top wall proximate the first endof the side wall, the joint including an upper portion and a lowerportion. Additionally, an opening is formed in the top wall, wherein theopening is located below the upper portion of the joint.

Preferably, the joint comprises a polymer-to-polymer bond.Alternatively, the joint comprises an adhesive.

In certain constructions, the joint has a first cross sectionalthickness and the top wall has a second cross sectional thickness, thefirst cross sectional thickness being greater than the second crosssectional thickness. It is envisioned that he first cross sectionalthickness can be at least twice the second cross sectional thickness.

It is envisioned that the top wall is formed from a first blank and theside wall is formed from a second, separate blank.

Preferably, the side wall circumferentially extends about thelongitudinal axis, and wherein the top wall is substantiallyperpendicular to the longitudinal axis.

In certain constructions, at least one of the side wall and the top wallis formed from a paper-based material selected from the group consistingof paperboard, corrugated board, cardboard, and combinations thereof.

The present disclosure is further directed to a container-lid assemblythat includes a container having a rim; and one of the previouslydescribed container lids positioned over the container such that the rimis received in the outwardly projecting sealing channel.

Preferably, the container is a drinking cup. It is envisioned that therim is a rolled rim.

The present disclosure is further directed to a container lid thatincludes a side wall and a top wall. The side wall is formed from afirst piece of paperboard and extends about a longitudinal axis andincludes longitudinally opposed first and second ends. The side walldefines a sealing channel between the first end and the second end, thesealing channel having an outer diameter. The top wall is formed from asecond piece of paperboard and is connected to the first end of the sidewall along a joint, wherein the sealing channel is located between thejoint and the second end. The side wall includes a flared portionpositioned between the sealing channel and the second end, a maximuminside diameter of the flared portion being greater than the sealingchannel outer diameter.

Preferably, the top wall is formed from a first blank and the side wallis formed from a second, separate blank. In certain constructions, theside wall circumferentially extends about the longitudinal axis, andwherein the top wall is substantially perpendicular to the longitudinalaxis.

Still further, the present disclosure is directed to a lid for acontainer that includes, among other elements, a paperboard side walland a paperboard top wall. The paperboard side wall is formed from afirst blank, wherein the side wall extends about a longitudinal axis andincludes longitudinally opposed first and second ends. The paperboardtop wall is formed from a second blank, wherein the first blank isdifferent from the second blank. The top wall is connected to the sidewall proximate the first end and the side wall includes an in-curled rimportion associated with the first end.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the presentinvention pertains will more readily understand how to employ thesystems and methods of the present invention, embodiments thereof willbe described in detail hereinbelow with reference to the drawings,wherein:

FIG. 1 illustrates one embodiment of the disclosed lid 10 wherein thetop wall 11 of the lid is recessed and includes an opening or openingstructure 15: FIG. 1A is a plan view of the lid, FIG. 1B is aperspective view, FIG. 1C is a cross sectional view showing the sealingchannel 17 and the joint section 18 between the top wall 11 and the sidewall 12 of the lid; and FIG. 1D is a cross sectional view showing astack of three lids;

FIG. 2 illustrates several embodiments of a lid wherein the top wall ofthe lid is recessed and a lower skirt 19 is provided. FIG. 2A is a crosssection view of the lid shown in FIG. 1. FIG. 2B is a cross section of alid 20 with a flared or bell-shaped skirt 29, for example formed byforming the skirt outward at point 29A or lower. FIG. 2C is a crosssection of a lid 30 with a top 31 and a lengthened and flared orbell-shaped skirt 39, for example made by forming the skirt outward atpoint 39A or lower;

FIG. 3A again illustrates the lid, while FIGS. 3B and 3C illustrateblanks for the side wall and top wall of the lid;

FIG. 4A illustrates a step in forming the side wall of the lid, whileFIG. 4B illustrates a step in forming the top wall of the lid;

FIG. 5A illustrates a further step in forming the side wall of the lid,while FIG. 5B illustrates a further step in forming the top wall of thelid;

FIGS. 6A to 6C illustrate steps in combining the side wall and top wallto form the lid;

FIGS. 7A and 7B illustrate a perspective view and a cross section viewof a lid showing additional features;

FIGS. 8A and 8B illustrate tools for forming certain features on theside wall of the lid;

FIGS. 9A and 9B illustrate tools being used to form certain features onthe side wall of the lid;

FIGS. 10A and 10B illustrate tools being used in a different mode ofoperation;

FIGS. 11A and 11B illustrate tools being used in yet another mode ofoperation;

FIGS. 12A and 12B illustrate tools being used in still another mode ofoperation;

FIGS. 13A to 13D illustrate cross sections of several types of cup lids;

FIG. 13E illustrates a cross section of the Inmaco lid;

FIG. 14 illustrates a further embodiment of the disclosed lid 110wherein the top wall 111 of the lid is recessed and includes an openingor opening structure 115: FIG. 14A is a plan view of the lid, FIG. 14Bis a perspective view, FIG. 14C is a cross sectional view showing thesealing channel 117 and the joint section 118 between the top wall 111and the side wall 112 of the lid; and FIG. 14D is a cross sectional viewshowing a stack of three lids; and

FIGS. 15A and 15B illustrate the blanks used to form the container lidillustrated in FIGS. 14A-14D.

These and other aspects of the subject invention will become morereadily apparent to those having ordinary skill in the art from thefollowing detailed description of the invention taken in conjunctionwith the drawings.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Disclosed herein are detailed descriptions of specific embodiments ofthe paper-based container lids, methods and assemblies of the presentinvention. It will be understood that the disclosed embodiments aremerely examples of the way in which certain aspects of the invention canbe implemented and do not represent an exhaustive list of all of theways the invention may be embodied. Indeed, it will be understood thatthe systems, devices and methods described herein may be embodied invarious and alternative forms. The figures are not necessarily to scaleand some features may be exaggerated or minimized to show details ofparticular components. Well-known components, materials or methods arenot necessarily described in great detail in order to avoid obscuringthe present disclosure. Any specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as abasis for the claims and as a representative basis for teaching oneskilled in the art to variously employ the invention.

The present disclosure now will be described more fully, but not allembodiments of the disclosure are necessarily shown. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the disclosure without departing from the essentialscope thereof.

The paper-based container lid of present disclosure includes, amongother elements, a top wall and a side wall. The side wall includes afirst end and a second end, the first end connecting to the top wall.The side wall further including a sealing channel for sealingly engaginga rim of the container and securing the lid to the container, whereinthe top wall and the side wall are formed from separate blanks.

The disclosed lid provides a cover for the container to inhibit spillageand may reduce heat transfer between the packaged contents and thesurrounding atmosphere. The disclosed lid may be manufacturedeconomically using modified existing converting machines (orcustom-built machines) for the production of containers, such as cups orbowls, wherein each container is made of at least two main components: abottom wall of the container and a side wall of the container. The lidof present disclosure may be formed in the similar manner as thecontainer, namely the lid is made of at least two main components (a topwall and a side wall).

The disclosed paper-based lids may be used with containers of varioustypes. They may be used for fluid containers, such as cups or bowls.

In one embodiment, the container is a drinking cup. In one embodiment,the lid is for disposable cups of the type commonly used as carry-outcontainers for beverages such as coffee and the like. Such cups arecommonly made of Styrofoam or paper. In one embodiment, the disclosedlid is for the drinking cup containing hot fluid, such as coffee cup.

In one embodiment, the container is a drinking cup having a generallycircular upper rim with a bead formed on it. Those skilled in the artwill readily appreciate that the lids disclosed herein can be adaptedfor use with containers having rims which are not circular, but may beother shapes, such as, but not limited to, rectangular.

The top wall of the lid provides coverage for the contents inside thecontainer. The side wall of the lid provides an engagement to thecontainer, a seal to prevent leakage of packaged fluid/contents, andstructural rigidity. The sealing channel formed in the side wallmechanically secures the lid in place to the container and provides aseal between the lid and the container. The sealing channel is sized tofit the container rim, providing a snug friction fit between the lid andthe container. Although the sealing channel is shown in representativefigures as an curved channel, one skilled in the arts appreciates thatthe radius or cross-section of sealing channel may be modified toaccommodate the shape of the container rim. For example, thecross-section of sealing ring may be square, rectangular, oval, oroblong.

As described herein below, in certain embodiments the container is adrinking cup and the lid may include at least one opening structure toenable drinking from the cup without removal of the lid. The openingstructure may be formed in the top wall of the lid. In one expression,the top wall of the lid may further include a recess adjacent theopening structure to accommodate the upper lip of the user drinking fromthe cup.

A variety of opening structures may be used for the lid of presentdisclosure. In one embodiment, the drinking opening structure may be acut out structure. In one embodiment, the drinking opening structure maybe score lines defining a movable portion that the user could penetrateor fold to gain access to the interior of the cup.

In one embodiment wherein the container is a drinking cup, the disclosedlid may include a vent hole formed on the top wall, such as near thecenter of the top wall, to enable air to flow into the cup as the userdrinks from the cup to facilitate the flow of liquid out of the cupthrough the drinking opening structure.

The top wall of the disclosed lid may have out-of-plane features forpositioning the drinking opening structure, for appearance, to containliquid that ends up above the lid and drain it back into the cup, or forcombinations of these reasons. The top wall may include a debossed(i.e., depressed) feature which surrounds the drinking hole.Additionally, the top wall may include an embossed (raised) feature orfeatures (not shown). The top wall may include both depressed and raisedfeatures. Such depressed or raised features may be formed in the topwall either in the blank (flat) stage of FIG. 3C, or in the intermediateformation stage shown in FIGS. 4B and 5B, or during or after assembly asshown in FIGS. 6B and 6C.

Various connection methods may be used in the present disclosure to jointhe lid top wall and the first end of the lid side wall. Examples ofsuch connections may include, but are not limited to, a lap-joint, awrapped edge, or combination thereof. Bonding may be achieved with apoly-poly heat seal and/or an adhesive. The lid side wall may be formedfrom a first blank, and the lid top wall from a second blank separatefrom the first blank. By “joint” in the present disclosure is meant thearea where two originally separate pieces or blanks of material areunited or connected together.

When desired, the second end of the lid side wall may include a rolledor folded edge to provide stability and alignment when sealing thedisclosed lid to the container.

In one embodiment, the disclosed lid may include an outward skirtstructure to facilitate the engagement of the lid onto the container. Asthe lid is pushed downwardly onto the rim of the container, the skirtstructure aids in centering the lid and in engaging the sealing channelwith the container rim. Furthermore, the skirt may provide a contactsurface for removing the disclosed lid from the container.

The present disclosure also describes an apparatus that includes:

a die for receiving a container or a container lid, the die including anannular recess formed in an internal surface thereof, a channel formingtool including a protruding structure having a shape complementary withthe annular recess of the die, the protruding structure cooperating withthe annular recess of the die and engaging a portion of the sidewall ofcontainer or the container lid, whereby when the channel forming tool isplaced inside the container or the container lid positioned in the die,the protruding structure of the tool presses at least a portion of thecontainer or container lid into the recess such that a sealing channelis formed on the container or container lid where the protrudingstructure abuts the annular recess, and wherein either the die, or thechannel forming tool, or both are rotated during the formation ofsealing channel. In one embodiment, the portion of the container or thelid being engaged by the channel forming tool includes a side wall ofthe container or the lid.

The disclosed apparatus is suitable for forming a sealing channel in acontainer or a container lid that provides an enhanced sealing betweenthe container and the lid.

The disclosed apparatus may be adapted to be fitted to the convertingmachines commonly used for the production of containers or containerlids.

The depth, shape and the width of the sealing channel may be adjusted toaccommodate the end use applications of the containers. These may beachieved by modifying the depth, shape and the width of the protrudingstructure on the channel forming tool. The disclosed apparatus mayprovide a sealing channel with increased depth to allow for an improvedsealing between the container and the lid.

The disclosed apparatus may be used for the containers and/or containerlids of various types. The containers may be for fluid containers, suchas cups or bowls.

In one embodiment, the container is a drinking cup having a generallycircular upper rim with a bead formed on it. Paperboard drinking cupsmay typically have a rolled bead on their upper edge. However, thedisclosed lid may also be used for cups made from other materials whichmay have different forms of an upper rim, such as a molded rim for aStyrofoam cup.

Referring now to the drawings wherein FIG. 1 illustrates one embodimentof the disclosed container lid which has been identified using referencenumeral 10. Lid 10 includes a top wall 11 and a side wall 12, which maybe formed as separate pieces and then connected together to form the lid10. The side wall 12 may extend (e.g., circumferentially extend) about alongitudinal axis L (FIG. 1B), and may include a first end 13longitudinally opposed from a second end 14. The top wall 11 may betransverse to the longitudinal axis L, and may be connected to the firstend 13 of the side wall 12 at a joint section 18 to form the lid 10.

The side wall 12 of the lid 10 may include a sealing channel 17, whichcontinuously (e.g., circumferentially) extends about the side wall 12.Those skilled in the art will readily appreciate that sealing channel 17can be discontinuous without departing from the scope of the presentinvention. The sealing channel 17 is sized and shaped to closely receivethe rim “R” of a container, as shown in FIG. 13A, thereby securing thelid 10 to the container.

Referring to FIGS. 1A and 1B, the top wall 11 may include an opening 15that provides an access to the contents inside the container withoutremoval of the lid. As shown in FIGS. 1B-1C, the top wall 11 may beformed such that the top wall surface is lower than the joint section 18of the top wall 11 and the side wall 12. As shown in FIG. 1C, the sidewall 12 may slope outward at an angle α1, which may help with puttingthe lid on a cup, and may allow better stacking of the lids as shown inFIG. 1D. The height Hs of the stack may be determined in large part bythe rim height Hr. The rim height Hr and skirt height h1 may be chosenaccording to manufacturing preference. In one example, the rim height Hrmay be approximately 5 mm and the skirt 19 height h1 approximately 21mm. The angle α1 may be chosen according to manufacturing preference. Inone example, α1 may be about 7 degrees.

FIG. 2A again illustrates lid 10. FIG. 2B illustrates a lid 20 with aside wall 22 having a flared skirt 29, and FIG. 2C shows another lidwith a longer side wall 32 also flared. By “flared” is meant that theside wall 22 is belled radially outward beyond the usual slope α1 of theside wall. For example, the flared side wall skirt 29 may extendgenerally at a flare angle β1 relative to the side wall slope angle α1.In other words, while the joint 28 may slope inwards at an acute angleα1 relative to the top wall 21, the flare portion 29 may have a slopeangle α2 that is greater than α1. The angle α2 may be approximatelyα1+β1.

As shown in FIG. 2B, the diameter Di of the inside of the flare shouldbe greater than the diameter Do of the outside of the sealing channel27, so that the flare and the sealing channel are not in contact witheach other. This may reduce friction or sticking between the lids.Friction or sticking is inconvenient to the user, and may result in avariable stacking height for the lids. With reduced friction betweenlids, the stack height Hs can be more consistent (at approximately Hrtimes the number of lids in the stack). The sealing channel may belocated just below the top wall as shown in FIG. 2, or it may be locatedfurther downward from the top wall.

The seam (see area S in FIGS. 3A, 4A, 5A) of the side wall 22 (i.e., thearea where the material overlaps to form a lap joint) may be compressedso that the step height (difference in thickness) at the joint isminimized. Minimizing the step height will minimize the potential forleakage in the channel in the area of the seam. Such seam compressionmay be done while the side wall is being shaped (e.g. FIG. 5A) or whilethe sealing channel is being made (e.g. FIG. 9A for example). One way toachieve relatively constant side wall thickness is to pass the side wall22 (e.g. at FIG. 5A) between a pair of rollers separated by a set gapapproximately equal to the board thickness. Thus, most of the side wallthickness may be relatively undisturbed (at a single thickness) but theotherwise double thickness at seam S may be reduced to near or equal toabout 1.5 times a single thickness). Another way to achieve relativelyconstant wall thickness at seam S is to preferentially press or clampthe seam area. The overlap area may also be skived (at least one layerbeing thinned) to help reduce its thickness.

FIG. 3A shows an embodiment of the disclosed container lid similar tothat in FIG. 2B. Lid 20 includes a top wall 21 and a side wall 22 thatincludes a first end 23 and a second end 24. As shown in FIG. 3, the topwall 21 includes a cover 21A and a vertical wall 21B extending upwardfrom the cover 21A, and the vertical wall 21B is received and sealedbetween two plies of the side wall 22 at its first end 23 as jointsection 28 to form a lid 20. The top wall may include an opening (see 15in FIG. 1) that provides an access to the contents inside the containerwithout removal of the lid. The joint section 28 may thus have threeplies. The joint section may 28 have a cross sectional thickness greaterthan the cross sectional thickness of either top wall 21 or side wall22. The joint section 28 may have a cross sectional thickness at leasttwice the thickness of either of the top wall 21 or the side wall 22.

FIG. 3B shows an example blank for making the side wall 22. For a lidhaving a diameter D, rim height Hr, and skirt height h1, the side wallblank may have a length of about πD, and a width of about h1+2Hr. Anoverlap distance C may be provided at an end of the blank for forming alongitudinal seam. The side wall 22 may be made from paperboard, such asa paperboard cup stock. As a non-limiting example, the caliper may beabout 16.5 mils (0.016″). The paperboard may lack any clay coating, andmay be coated on each side with about 0.75 mils to 1.0 mils of LDPE (lowdensity polyethylene). In one embodiment, no additional heat sealing oradhesive components are used besides the LDPE and any associated tielayer(s).

FIG. 3C shows a circular blank for making the top wall 21. For a lidwith a diameter D and rim height Hr, the diameter of the blank may beapproximately D+2Hr. The top wall 21 may be made from paperboard, suchas a paperboard cup stock. As a non-limiting example, the caliper may beabout 9.3 mils (0.0093″). The paperboard may lack any clay coating, andmay be coated on the side to face the inside of the cup with about 0.75mils to 1.0 mils of LDPE (low density polyethylene), and on the outerside with about 0.5 mils to 1.0 mils of LDPE. In one embodiment, noadditional heat sealing or adhesive components are used besides the LDPEand any associated tie layer(s).

FIG. 4A shows a step in forming the side wall 22 of the container lid bybringing together (arrow M1) the ends of the side wall blank of FIG. 3B,to form a band or loop. This may be achieved, for example, by wrappingthe side wall blank around a cone shaped mandrel and adhering the endstogether, such as with an adhesive or heat. FIG. 4B shows a step informing the top wall wherein the top wall 21 of the lid by turningupward (arrow M2) the perimeter of the circular blank. This may beachieved, for example, by placing the top wall 21, in the form of adisk, over a circular opening or circular cavity and using a pressingtool or vacuum to press or draw the interior area of the disk into theopening or cavity.

FIG. 5A shows a further step in forming the side wall 22 of thecontainer lid by overlapping the ends of the side wall blank of FIG. 4B,along seam area S, which may overlap a distance C. FIG. 5B shows anoptional further step in forming the top wall wherein the top wall 21may be turned upward about 90 degrees (or even slightly further to matchthe slope angle of the side wall.

FIG. 6A shows a further step in forming the lid where the top wall 21 ismoved (arrow M3) upward inside the loop of the side wall 22, where (asshown in FIG. 6B for this example) the plane of the top wall 21 may beabout ⅓ up from the bottom of the side wall 22 and about ⅔ down from thetop edge of the side wall 22. Next, the top edge of side wall 22 may befolded down and inward (arrow M4) over the upstanding perimeter of thetop wall 21. This may be achieved, for example by using rollers or othertools to bend the top edge inward and downward, and then using a pair ofwheels to press the folded top edge of the side wall into tight sealingcontact with the upstanding perimeter of the top wall as shown by arrowsM5 in FIG. 6C. The resulting structure is shown in FIG. 6C. The triplelayer of the rim of the lid may be sealed together by heat and pressureand/or adhesive and pressure.

FIGS. 7A and 7B show a variation on the lid 40 where indents are formedin the side wall 42. The indents may include formed areas 46A and 46Bthat are formed inwardly and outwardly with respect to one another. Analternate description of the indents is that the inward formed areas 46Aare inwardly formed creases, while the outward formed areas are columnarregions positioned at a larger radius than the inwardly formed creases.While the upper boundary of the sealing channel 17 may thus be acontinuous circle as shown, the lower boundary may be a discontinuousseries of arcs joined by the columnar regions. When the lid 40 is placedonto a cup, downward pressure may be applied to seat the sealing channelonto the cup. The columnar regions 46B may serve to prevent the sealingchannel 17 and/or regions 46A from being crushed or collapsed by thispressure.

Lid 40 may also have a flared side wall 49 as described previously.

When appropriate, the surface of the disclosed lid may be made frompaperboard coated with various materials to impart desired properties.For example, the lid may be made of water-resistant coated paper such asa poly-coated paper or board. The coating may be applied in advance, forexample on-machine or on-coater. The poly-coated surface may faceinwardly (toward the contents which the lid would cover) or the polycoating may be on both surfaces. The paperboard itself may be chemicallysized to minimize wicking of liquids including but not limited to hotcoffee or other hot liquids.

In one embodiment, the disclosed paper-based lid may include apolymeric-based coating on one side or both sides. The polymer coatingmay impart liquid resistance to the paper and may facilitate sealing thetop wall to the side wall. A heat sealable coating may be used.Optionally a clay coating or other coating may be provided. Suchcoatings may provide useful properties, such as improved printingcharacteristics for printing customer information or other indicia onthe lid.

Various paper-based substrates may be used for the top wall of thedisclosed lid. Examples of such materials include, but are not limitedto, paperboard, and combinations of paperboard with other materials.

Various paper-based substrates may be used for the side wall of thedisclosed lid. Examples of such materials include, but are not limitedto, paperboard, and combinations of paperboard with other materials.

In one embodiment, the top wall and the side wall of the disclosed lidsare made of the same type of the substrate.

In one embodiment, the top wall and the side wall of the disclosed lidsare made of different types of the substrates.

FIGS. 8 and 9 show one embodiment of an apparatus for forming a sealingchannel in a cup lid. The apparatus includes a supporting die 101 forreceiving a container or a container lid, a channel forming tool 102that includes an annular protruding structure 103, and a rotating tool104.

The supporting die may include more than one component to facilitate theremoval of the container or lid from the die after the sealing channelis formed thereof. In FIG. 8, the supporting die 101 includes components101A and 101B that may be assembled together to receive the container orlid, and may be easily disassembled to facilitate the removal of thecontainer or lid from the supporting die 101. It is understood that thesupporting die may include more than two components, and the presentdisclosure is in no way limited to only the apparatus with thesupporting die composed of two components as shown in FIG. 8.

Referring to FIGS. 8 and 9, the supporting die 101 includes an annularrecess 105 formed in its internal surface, wherein the annular recess105 has a complementary shape to that of the outer edge of theprotruding structure 103 on the channel forming tool 102.

FIG. 8 shows the apparatus not yet holding the cup side wall 42 orchannel forming tool, which are added in FIG. 9. The lid may be held inthe tool by vacuum or by gripping fingers (not shown). The channelforming tool suitable for use in the disclosed apparatus may include oneor more protruding structures. FIG. 9 shows the channel forming tool102) with only one annular protruding structure 103). However, oneskilled in the art recognizes that the channel forming tool of thedisclosed apparatus may include more than one protruding structure.

The disclosed apparatus may include a moving tool to rotate thecontainer or the container lid. FIG. 9 shows one embodiment of thedisclosed apparatus wherein the supporting die 101A, 101B rotates (arrowM6) the lid (side wall 42, shaded) while channel forming tool 102 ismoved (arrow M7) so that the annular protruding structure 103 contactsthe lid side wall 42 to gradually displace the side wall into theannular recess to form the desired sealing channel. The annularprotruding structure 103 as shown here may be a disk-shaped wheel thatmay be rotated by contact with the channel forming tool 102, or theprotruding structure 103 may rotate on a bearing upon channel formingtool 102. In other embodiments the annular protruding structure 103 maynot rotate or may rotate in synchronization with the moving tool.

The supporting die 101A, 101B may be rotated in a milling machine, andthe channel forming tool 102 moved relative to the work on the millingmachine slide or table. Use of a milling machine may be practical intesting situations. Instead of using a milling machine, and/or forproduction, any equipment that provides the desired actions may be usedto produce the lid. Automated equipment may be utilized.

Although the apparatus is shown with rotation M6 about a horizontalaxis, rotation could also be about a vertical or other axis. Althoughthe axis of the channel forming tool 102 (or rotating tool) is shown tobe parallel to the axis of rotation M6, there may be instances where thechannel forming tool 102 and/or tool 104 are at an angle to the axis ofrotation M6. For example, if it is desired to form the sealing channelclose to the lid top 41, the channel forming tool 102 and/or tool 104may be held at an angle so that annular protruding structure does notrub on the lid top 41, or contact any depressed (inward) features thatmay optionally be present on the lid top 41. Instead of, or in additionto, using a rotating or rolling tool to form the sealing channel, thesealing channel may also be create by pressing the paperboard between atool and a backing surface.

The annular protruding structure 103 may be moved a set distance (aswith a milling machine table or slide, using markings on a lead screw orusing a digital readout). Thus a set gap may be achieved between theannular protruding structure 103 and the annular recess, so that theside wall 42 at the sealing channel has a relatively uniform thickness.This may entail compressing the seam S more than the rest of the sidewall.

Alternately as shown in FIG. 10, the container or lid (shaded) and thesupporting die 101 may remain still while the channel forming tool 102with its annular protruding structure 103 moves and rotates (arrow M8)to gradually create a sealing channel on the container or lid.

Alternatively, in one embodiment of the disclosed apparatus, both thechannel forming tool 102 and the supporting die 101 may be moved inrelation to one another in any direction so long as their movementsfacilitate a gradual formation of sealing channel on the container orlid.

In one embodiment of present disclosure, in operation a container or alid is positioned in a supporting die with its side wall against aninternal surface of the die. Then, the channel forming tool is placedinside the container or lid against its side wall. The rotating toolmoves the die, or the channel forming tool, or both in relation to oneanother such that the protruding structure of the channel forming toolpresses a portion of the container or lid side wall abutting the recessof the die to create an annular sealing channel on the container or lidside wall. The resulting container or lid is then removed from thesupporting die, either with or without a need for disassembly of thesupporting die.

The annular protruding structure 103, instead of being a circular diskas shown in FIGS. 8-10, may be a disk which include teeth or notches(not shown). Alternately or in addition, teeth or notches may be formedon the moving tool 101A, 101B for example as shown by notches 107 inFIG. 11B formed in annular recess 105. Teeth or notches may be utilizedto form indents 46A, 46B shown in FIGS. 7A, 7B. Alternately, or inaddition, raised or depressed areas may be formed in the annular recess105. However, it may be easier to form such features on the protrudingstructure 103. The protruding structure 103 and supporting tool 101 maybe rotated in synchronization to form indents 46A, 46B.

FIG. 12 shows one embodiment of the disclosed apparatus wherein thesupporting die 101A, 101B rotates (arrow M6) the lid (side wall 42,shaded) while a flare forming tool 109 is moved (arrow M7) so that aconical protruding structure 109B (or other suitably shaped tool)contacts the lid side wall 42 to displace the side wall into abell-shaped or flared edge 29 (see FIG. 2B) below the sealing channel.The bell-shaped or flared edge 29 may help guide the lid onto the cup.The flare forming tool may be rotated by contact with the channelforming tool 102 or the lid, or the conical protruding structure 109Bmay rotate on a bearing upon tool 109A. In other embodiments the flareforming tool 109 may not rotate or may rotate in synchronization withthe moving tool. In other embodiments the supporting die 101A, 101B mayhave an enlarged open end to cooperate with the flare forming tool 109in forming the flare.

FIG. 13 shows cross sections of several cup lids. FIG. 13A illustrates across section of the disclosed cup lid 20 seated on the rim R of a cup.The cup lid 20 includes the top wall 21 and side wall 22 joined togetherat joint 28. The formed sealing channel 27 fits snugly on the rim R. Theside wall 22 may be flared as at 29.

FIG. 13B shows an existing plastic lid 50 that has a sealing channel 57with an approximately circular shape, and also a flared section 59. Ascan be readily seen, the sealing channel is arranged the rim of the cupis inserted upward into the channel. FIG. 13C shows another existingplastic lid 60 that has a downwardly facing sealing channel 67 with anapproximately rectangular shape, and also a flared section 69. FIG. 13Dshows an existing plastic lid 70 that has a sealing channel 77 with anapproximately rectangular shape on an inner quadrant, and anapproximately circular shape on an outer quadrant, and also a flaredsection 79. FIG. 13E provides a cross-sectional view of the interactionbetween the Inmaco lid and a convention beverage cup. As notedpreviously, the bead formed in the sidewall around the circumference ofthe Inmaco lid 80 secures the lid 80 to an appropriately sizedcontainer. The fit is fairly tight radially, i.e. there is a close matchbetween the outer diameter of the container rim and the inner diameterof the lid. However, there is not a tight fit axially; the lid can moveup and down and thus it is unlikely that it provides good leakresistance. Moreover, since the sidewall of the lid in the sealing zoneis flat and rim is curved there is not mating contact between thesidewall and rim surfaces, and thus the seal is poor.

In the construction of the present invention, the channel 27 formed inthe sidewall 22 of the lid 20 acts against the radially outward pressurecreated by the rim of the cup creating an enhanced seal between themating surfaces. The prior art embodiments shown in FIGS. 13B through13E do not exhibit such a mechanical interaction.

Referring now to FIGS. 14A-14D there is illustrated a further embodimentof the container lid of the present disclosure which has been identifiedas reference numeral 100. Lid 100 includes, inter alia, a paperboardside wall 112 formed from a first blank 130 (see FIG. 15B). The sidewall 112 extends about a longitudinal axis “L” and includeslongitudinally opposed first and second ends 113/114. A top wall 111 isformed from a second blank 140 (see FIG. 15A). As noted previously, theblanks 130/140 can be made from the same material or they can be madefrom different materials. For example, in certain embodiments, theblanks are both paperboard.

As shown in FIG. 14C, the top wall 111 of the lid 100 is connected tothe side wall 112 proximate the first end 113. Top wall 111 includes anopening 115 formed therein which will allow a user access to thecontents of the container without having to remove lid 100. Thoseskilled in art will recognize that an “opening” can include a holeprovided in the lid during the manufacturing process or an area ofmaterial, such as a region surrounded by a perforation line, which isadapted to be removed by the user of the lid.

As best viewed in FIG. 14C, lid 100 further includes a sealing channel117 formed in the side wall 112 between the first end 113 and the secondend 114. In the embodiment of the present disclosure shown in thisfigure, the sealing channel 117 projects radially outward from thelongitudinal axis L.

The side wall 112 of the lid includes a substantially vertical seam “S”that extends between the first end 113 and the second end 114 of theside wall 112. The seam S is compressed to reduce its step height. Asshown in FIG. 14B, it is preferable to have the opening 115 positionedopposite of the seam S, so as to decrease the potential for leakagealong the seam line when a user is drinking from the container, forexample.

The side wall 112 of lid 100 includes an inner surface 112 i which has apolymer coating. The top wall 111 includes a lower surface 111L and anupper surface 111U which each include a polymer coating. The uppersurface 111U of the top wall 111 is connected to the inner surface 112 iof the side wall 112 by a polymer-to-polymer bond and the lower surface111L of the top wall 111 is connected to the inner surface 112 i of theside wall 112 by a polymer-to-polymer bond. Those skilled in the artwill readily appreciate that other methods of joining the top wall tothe bottom wall, including methods that use an adhesive rather than apolymer-to-polymer bond can be used in the present lid construction.Moreover, the outer surface of the side wall may also include a polymercoating to facilitate a polymer-to-polymer bond along the seam “S”.

Lid 100 includes a joint section 118 defined by where the first end 113of the side wall 112 is connected to the top wall 111. The joint section118 includes a top end 122 that forms a lid rim 124 and the lid rim 124includes a substantially rounded section or in-curled section 126. Thesubstantially rounded section 126 of the lid rim 124 is oriented towardthe longitudinal axis L and provides a surface with more pleasingmouth-feel for the user. The opening 115 is formed in the lid 100 belowthe rim 124. As shown in FIG. 14A, a second opening 144 is provided inthe top wall 111 of the lid 100 for venting.

The joint section 118 further includes a middle section 128 below thetop end 122. The rim 124 has a width associated therewith and the middlesection 128 has a width associated therewith. As shown in the figure,the width of the rim 124 is greater than the width of the middle section128.

As shown in FIG. 14C, the joint section 118 of lid 100 includes a bottomend 129 below the middle section 128. The bottom end 129 flares towardthe longitudinal axis L and facilitates creating the joint between thetop wall 111 and the side wall 112.

Moreover, the top wall 111 includes a debossed section 132 and theopening 115 is located within the debossed section 132. The top wall 111further includes an embossed section 134 located adjacent to and aroundthe periphery of the debossed section 132. The combination of these twofeatures creates and area with liquid can collect and return to thecontainer through opening 115.

As shown in FIG. 14C, the outwardly projecting sealing channel 117 hasan upper portion associated therewith, and the top wall 111 is connectedto the side wall 112 adjacent to the upper portion of the outwardlyprojecting sealing channel 117.

Referring now to the blank 130 shown in FIG. 15B. Blank 130 includes aflap section 137 separated from a flange section 138 by fold line 160.When the lid is assembled, flap section 137 is folded over the flangesection 138 to create the lid rim 124. Below the flange section 138 is asection of material that is bound between dashed lines 162 and 164. Thissection of material is to create the sealing channel 117. Between dashedlines 164 and 166 is a section of material which is used to create afirst flared section 146 (see FIG. 14B) in the side wall 111. A secondflared section 148 is created in the sidewall between dashed lines 166and 168 and the material located below dashed line 168 may be trimmedoff.

As shown in FIG. 15A, blank 140 includes a line 142 which represents theline on which the upwardly projection peripheral flange 145 is formed inthe top wall 111 either by folding or pressing. During the assemblyprocess for certain embodiment of the present invention, peripheralflange 145 is sandwiched between the flange section 137 and the flapsection 138 of the side wall 112.

Referring to FIG. 14D which illustrates three lids 100A, 100B and 100Cin a stacked arrangement. By flaring outwardly the second end 114 of theside wall 112, the stack height of the lids can be reduced. The outwardslope may also help with putting the lid on a cup. As described withrespect to FIG. 1D, the height Hs of the stack may be determined inlarge part by the rim height Hr. The rim height Hr and skirt height h1may be chosen according to manufacturing preference.

As described with respect to FIG. 2B, the diameter Di of the inside ofthe flare should be greater than the diameter Do of the outside of thesealing channel 117, so that the flare and the sealing channel are notin contact with each other. This may reduce friction or sticking betweenthe lids. Friction or sticking is inconvenient to the user, and mayresult in a variable stacking height for the lids. With reduced frictionbetween lids, the stack height Hs can be more consistent (atapproximately Hr times the number of lids in the stack). The sealingchannel 117 may be located just below the top wall as shown in FIG. 14C,or it may be located further downward from the top wall.

The containers suitable for use in the present disclosure may includepaper-based materials, plastics, composite materials, or combinationsthereof. Various paper-based substrates may be used for the containers.Examples of such materials include, but are not limited to, paperboard,corrugated board, cardboard, and combinations thereof.

It is believed that the present disclosure includes many otherembodiments that may not be herein described in detail, but wouldnonetheless be appreciated by those skilled in the art from thedisclosures made. Accordingly, this disclosure should not be read asbeing limited only to the foregoing examples or only to the designatedembodiments.

What is claimed is: 1) A lid for a container, comprising: a) apaperboard side wall formed from a first blank, wherein the side wallextends about a longitudinal axis and includes longitudinally opposedfirst and second ends; and b) a paperboard top wall formed from a secondblank, wherein the first blank is different from the second blank, i)wherein the top wall is connected to the side wall proximate the firstend, and ii) wherein the top wall includes an opening therein. 2) Thelid for a container as recited in claim 1, further comprising a sealingchannel formed in the side wall between the first end and the secondend. 3) The lid for a container as recited in claim 2, wherein thesealing channel is projects radially. 4) The lid for a container asrecited in claim 1, further comprising a substantially vertical seambetween the first end and the second end of the side wall. 5) The lidfor a container as recited in claim 4, wherein the seam is compressed.6) The lid for a container as recited in claim 4, wherein the opening ispositioned opposite of the seam. 7) The lid for a container as recitedin claim 1, a) wherein the side wall includes an inner surface, whereinthe inner surface includes a polymer coating, b) wherein the top wallincludes a lower surface and an upper surface, wherein the lower surfaceand the upper surface each include a polymer coating, c) wherein theupper surface of the top wall is connected to the inner surface of theside wall by a polymer-to-polymer bond, and d) wherein the lower surfaceof the top wall is connected to the inner surface of the side wall by apolymer-to-polymer bond. 8) The lid for a container as recited in claim1, a) wherein a joint section is defined by where the first end of theside wall is connected to the top wall, b) wherein the joint sectionincludes a top end, c) wherein the top end forms a lid rim, and d)wherein the lid rim includes a substantially rounded section. 9) The lidfor a container as recited in claim 8, wherein the substantially roundedsection of the lid rim is oriented toward the longitudinal axis. 10) Thelid for a container as recited in claim 8, wherein the joint sectionfurther includes a middle section below the top end, wherein the rim hasa width associated therewith, wherein the middle section has a widthassociated therewith, and wherein the width of the rim is greater thanthe width of the middle section. 11) The lid for a container as recitedin claim 8, wherein the joint section further includes a bottom endbelow the middle section, and wherein the bottom end flares toward thelongitudinal axis. 12) The lid for a container as recited in claim 8,wherein the opening is located below the rim. 13) The lid for acontainer as recited in claim 1, wherein the top wall includes adebossed section, and wherein the opening is located within the debossedsection. 14) The lid for a container as recited in claim 13, wherein thetop wall includes an embossed section located adjacent to the debossedsection. 15) The lid for a container as recited in claim 2, wherein asection of the side wall above the sealing channel is oriented towardthe longitudinal axis and wherein a section of the side wall below thesealing channel is oriented away from the longitudinal axis. 16) A lidfor a container, comprising: a) a paperboard side wall formed from afirst blank, wherein the side wall extends about a longitudinal axis andincludes longitudinally opposed first and second ends, i) wherein asealing channel is formed in the side wall between the first end and thesecond end, ii) wherein a substantially vertical seam is formed betweenthe first end and the second end of the side wall, iii) wherein the sidewall includes an inner surface, wherein the inner surface includes apolymer coating; and b) a paperboard top wall formed from a secondblank, wherein the first blank is different from the second blank, i)wherein the top wall includes an opening therein. ii) wherein the topwall includes a lower surface and an upper surface, wherein the lowersurface and the upper surface each include a polymer coating, and iii)wherein the top wall is connected to the side wall proximate the firstend to define a joint section, (1) wherein the upper surface of the topwall is connected to the inner surface of the side wall by apolymer-to-polymer bond, and (2) wherein the lower surface of the topwall is connected to the inner surface of the side wall by apolymer-to-polymer bond. 17) The lid for a container as recited in claim16, wherein the sealing channel projects radially. 18) The lid for acontainer as recited in claim 16, wherein the seam is compressed. 19)The lid for a container as recited in claim 16, wherein the jointsection includes a top end forming a lid rim having a substantiallyrounded section. 20) The lid for a container as recited in claim 16,wherein the top wall includes a debossed section, and wherein theopening is located within the debossed section.